High Speed Turning of Ti-6Al-4V Alloy with Straight Cemented Carbide and PVD Coated Carbide Tools

2011 ◽  
Vol 496 ◽  
pp. 92-97 ◽  
Author(s):  
You Sheng Li ◽  
J. X. Deng ◽  
Steve Ebbrell ◽  
Michael N. Morgan ◽  
X.J. Ren
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Cemented Carbide ◽  
Linear Regression Method ◽  
X Ray ◽  
Multiple Linear Regression Method ◽  
Energy Dispersive Microanalysis ◽  
Cemented Carbide Tools ◽  
Coated Carbide ◽  
Coated Carbide Tools

This work comparatively studied the performances of straight cemented carbide tools and PVD coated carbide tools in high speed dry turning of Ti-6Al-4V alloy. Systematic machining tests have been performed and the tool life data were analysed using multiple linear regression method to establish extended Taylor tool life models. The wear mechanisms for both tools have been investigated in detail through SEM observation and X-ray energy dispersive microanalysis (EDS).

Tool Wear and Surface Integrity in High Speed Milling of Forging and Cast TA15 Alloys with Coated Carbide Tools

2009 ◽  
Vol 626-627 ◽  
pp. 189-194
Author(s):  
P. Liu ◽  
Jiu Hua Xu ◽  
Yu Can Fu
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Milling ◽  
Alpha Titanium ◽  
Series Of Experiments ◽  
Coated Carbide ◽  
Coated Carbide Tools

TA15 (Ti-6.5Al-2Zr-1Mo-1V) is a close alpha titanium alloy strengthened by solid solution with Al and other component. A series of experiments were carried out on normal and high speed milling of TA15. The recommended tools for many years had been the uncoated tungsten carbide grade K. In this work, the tool life of coated carbide tools used in high speed milling of forging and cast titanium alloy was studied. Additionally, the wear mechanism of cutting tools was also discussed. Finally, surface integrity, including surface roughness, metallograph and work hardening, were examined and analyzed. The result shows that the surface quality of forging and cast machined by carbide cutter is similar, but the tool life of carbide in high speed milling of forging TA15 is longer than that in high speed milling of cast TA15.

Study on the Tool Wear of Coated Carbide Tool in High Speed Milling Titanium Alloy

2014 ◽  
Vol 800-801 ◽  
pp. 526-530 ◽  
Author(s):  
Shu Cai Yang ◽  
Yu Hua Zhang ◽  
Quan Wan ◽  
Jian Jun Chen ◽  
Chuang Feng
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
High Speed ◽  
Carbide Tool ◽  
High Speed Milling ◽  
Coated Carbide Tool ◽  
Fluid Environment ◽  
Coated Carbide ◽  
Coated Carbide Tools

The milling experiments were carried out using TiAlN and PCD coated carbide tools in high speed milling Ti6Al4V to compare and analyze tool wear and tool life of the two kinds of coating carbide tools. In addition, the effect of cooling and lubricating on tool wear is also studied. The results showed that fluid environment is not suitable for milling Ti6Al4V. PCD coating carbide tool can effectively increase the life of tool in high speed milling of Ti6Al4V.

A Study of the Sensitivity of Parameters Affecting Coated Tool Life in High Speed Milling Superalloy GH4169

2013 ◽  
Vol 651 ◽  
pp. 436-441
Author(s):  
Wei Wei Liu ◽  
Xu Sheng Wan ◽  
Yuan Yu ◽  
Feng Li ◽  
Hao Chen
Keyword(s):  
High Temperature ◽  
Tool Life ◽  
High Speed ◽  
Depth Of Cut ◽  
Linear Regression Method ◽  
Carbide Tool ◽  
High Temperature Alloy ◽  
High Speed Milling ◽  
Coated Carbide Tool ◽  
Coated Carbide

Through the orthogonal test of the TiALN coated carbide tool high-speed milling of high-temperature alloy GH4169, the empirical formula of the tool life are acquired by using multiple linear regression method. On the basis of this formula, studying the absolute sensitivity and relative sensitivity of TiALN coated carbide tool life for milling speed, depth of cut and feed; The results showed that in the process of high-speed milling of high-temperature alloy GH4169, tool life decreased with the increase of milling speed, feed and depth of cut; tool life is most sensitive to the change of milling speed; change of feed take second place and milling depth is the least sensitive.

scholarly journals A Fuzzy Evaluation of Tool Materials in the Turning of Marine Steels

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1710
Author(s):  
Qingzhong Xu ◽  
Jichen Liu ◽  
Gangjun Cai ◽  
Dewen Jiang ◽  
Jian Zhou
Keyword(s):  
Surface Roughness ◽  
Evaluation Method ◽  
Cutting Temperature ◽  
Tool Material ◽  
Cutting Performance ◽  
Cemented Carbide ◽  
Fuzzy Evaluation ◽  
Cemented Carbide Tools ◽  
Coated Carbide ◽  
Coated Carbide Tools

To recommend one suitable tool material for the cutting of marine steels under special conditions and requirements in emergency rescues of capsized steel ships, the cermet tools, cemented carbide tools and coated carbide tools were evaluated using a fuzzy evaluation method concerning cutting force, cutting temperature, surface roughness and tool wear. Experimental results indicate that the tool cutting performance was diverse and difficult to evaluate with a single evaluation index. The cemented carbide tools presented bad cutting performance with severe wear. Compared with the cemented carbide tools, the cermet tools showed excellent wear resistance with about 60.3% smaller tool flank wear value and good surface quality with about 46.8% smaller surface roughness. The coated carbide tools presented low cutting temperatures about 15.6% smaller than those of the cermet tools. The result of fuzzy evaluation demonstrates that the cermet tools presented the best cutting performance, followed by the coated carbide tools, and then the cemented carbide tools. The cermet tools are recommended to cut marine steels in emergency rescues of capsized steel ships.

scholarly journals Finishing Turning of Ni Superalloy Haynes 282

Metals ◽  
2018 ◽  
Vol 8 (10) ◽  
pp. 843 ◽  
Author(s):  
José Díaz-Álvarez ◽  
Antonio Díaz-Álvarez ◽  
Henar Miguélez ◽  
José Cantero
Keyword(s):  
Tool Life ◽  
Fatigue Properties ◽  
Machining Performance ◽  
High Pressure And Temperature ◽  
Nickel Based Superalloy ◽  
Aeronautical Industry ◽  
Cutting Zone ◽  
Cemented Carbide Tools ◽  
Coated Carbide ◽  
Coated Carbide Tools

Nickel-based superalloys are widely used in the aeronautical industry, especially in components requiring excellent corrosion resistance, enhanced thermal fatigue properties, and thermal stability. Haynes 282 is a nickel-based superalloy that was developed to improve the low weldability, formability, and creep strength of other γ’-strengthened Ni superalloys. Despite the industrial interest in Haynes 282, there is a lack of research that is focused on this alloy. Moreover, it is difficult to find studies dealing with the machinability of Haynes 282. Although Haynes 282 is considered an alloy with improved formability when compared with other nickel alloys, its machining performance should be analyzed. High pressure and temperature localized in the cutting zone, the abrasion generated by the hard carbides included in the material, and the tendency toward adhesion during machining are phenomena that generate extreme thermomechanical loading on the tool during the cutting process. Excessive wear results in reduced tool life, leading to frequent tool change, low productivity, and a high consumption of energy; consequentially, there are increased costs. With regard to tool materials, cemented carbide tools are widely used in different applications, and carbide is a recommended cutting material for turning Haynes 282, for both finishing and roughing operations. This work focuses on the finishing turning of Haynes 282 using coated carbide tools with conventional coolant. Machining forces, surface roughness, tool wear, and tool life were quantified for different cutting speeds and feeds.

scholarly journals Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771061 ◽  
Author(s):  
Duc Tran Minh ◽  
Long Tran The ◽  
Ngoc Tran Bao
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Minimum Quantity Lubrication ◽  
High Hardness ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Hard Milling ◽  
Minimum Quantity ◽  
Coated Carbide ◽  
Lubrication Conditions

In this article, an attempt has been made to explore the potential performance of Al2O3 nanoparticle–based cutting fluid in hard milling of hardened 60Si2Mn steel (50-52 HRC) under different minimum quantity lubrication conditions. The comparison of hard milling under minimum quantity lubrication conditions is done between pure cutting fluids and nanofluids (in terms of surface roughness, cutting force, tool wear, and tool life). Hard milling under minimum quantity lubrication conditions with nanofluid Al2O3 of 0.5% volume has shown superior results. The improvement in tool life almost 177%–230% (depending on the type of nanofluid) and the reduction in surface roughness and cutting forces almost 35%–60% have been observed under minimum quantity lubrication with Al2O3 nanofluids due to better tribological behavior as well as cooling and lubricating effects. The most outstanding result is that the uncoated cemented carbide insert can be effectively used in machining high-hardness steels (>50 HRC) while maintaining long tool life and good surface integrity (Ra = 0.08–0.35 µm; Rz = 0.5–2.0 µm, equivalent to finish grinding) rather than using the costlier tools like coated carbide, ceramic, and (P)CBN. Therefore, using hard nanoparticle–reinforced cutting fluid under minimum quantity lubrication conditions in practical manufacturing becomes very promising.

Comparative assessment between AlTiN and AlTiSiN coated carbide tools towards machinability improvement of AISI D6 steel in dry hard turning

2021 ◽  
pp. 095440622110373
Author(s):  
Anshuman Das ◽  
Miyaz Kamal ◽  
Sudhansu Ranjan Das ◽  
Saroj Kumar Patel ◽  
Asutosh Panda ◽  
...  
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Hard Turning ◽  
Flank Wear ◽  
Chip Morphology ◽  
Comparative Assessment ◽  
Carbide Tool ◽  
Crater Wear ◽  
Coated Carbide ◽  
Coated Carbide Tools

AISI D6 (hardness 65 HRC) is one of the hard-to-cut steel alloys and commonly used in mould and die making industries. In general, CBN and PCBN tools are used for machining hardened steel but its higher cost makes the use for limited applications. However, the usefulness of carbide tool with selective coatings is the best substitute having comparable tool life, and in terms of cost is approximately one-tenth of CBN tool. The present study highlights a detailed analysis on machinability investigation of hardened AISI D6 alloy die steel using newly developed SPPP-AlTiSiN coated carbide tools in finish dry turning operation. In addition, a comparative assessment has been performed based on the effectiveness of cutting tool performance of nanocomposite coating of AlTiN deposited by hyperlox PVD technique and a coating of AlTiSiN deposited by scalable pulsed power plasma (SPPP) technique. The required number of machining trials under varied cutting conditions (speed, depth of cut, feed) were based on L16 orthogonal array design which investigated the crater wear, flank wear, surface roughness, chip morphology, and cutting force in hard turning. Out of the two cutting tools, newly-developed nanocomposite (SPPP-AlTiSiN) coated carbide tool promises an improved surface finish, minimum cutting force, longer tool life due to lower value of crater & flank wears, and considerable improvement in tool life (i.e., by 47.83%). At higher cutting speeds, the crater wear length and flank wear increases whereas the surface roughness, crater wear width and cutting force decreases. Chip morphology confirmed the formation of serrated type saw tooth chips.

Comparative Experimental Research on Cutting Superalloy Used New Coated Carbide Tools

2010 ◽  
Vol 33 ◽  
pp. 173-176
Author(s):  
X.Y. Wang ◽  
S.Q. Pang ◽  
Q.X. Yu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Experimental Research ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Life Testing ◽  
Processing Efficiency ◽  
Comparative Tests ◽  
Coated Carbide ◽  
Coated Carbide Tools

The aim of this work is to investigate the machinability of new coated carbide cutting tools that are named C7 plus coatings under turning of superalloy GH2132. This achieved by analysis of tool life at different cutting conditions .Investigations of tool wear and tool life testing are intended to establish T-V formulas, and then analyzed the characteristics of coating . Through a series of comparative tests, Using TiAlN coatings as the contrast materialthe results show that the new coating tools that are named C7 plus coatings are suitable for cutting superalloy GH2132. The cutting speed and processing efficiency can be increased effectively.

Wear and breakage of TiAlN- and TiSiN-coated carbide tools during high-speed milling of hardened steel

Wear ◽  
2015 ◽  
Vol 336-337 ◽  
pp. 29-42 ◽  
Author(s):  
C.Y. Wang ◽  
Y.X. Xie ◽  
Z. Qin ◽  
H.S. Lin ◽  
Y.H. Yuan ◽  
...  
Keyword(s):  
High Speed ◽  
Hardened Steel ◽  
High Speed Milling ◽  
Coated Carbide ◽  
Coated Carbide Tools

Tool Wear of Aluminum/Chromium/Tungsten-Based-Coated Cemented Carbide in Cutting Hardened Steel

2015 ◽  
Vol 798 ◽  
pp. 377-383 ◽  
Author(s):  
Tadahiro Wada ◽  
Hiroyuki Hanyu
Keyword(s):  
Tool Wear ◽  
Cathode Material ◽  
Hardened Steel ◽  
Cemented Carbide ◽  
Coating Film ◽  
Carbide Tool ◽  
Micro Hardness ◽  
Cemented Carbide Tools ◽  
Coated Carbide ◽  
Coated Cemented Carbide

An aluminum/chromium based coating film, called (Al,Cr)N coating film, has been developed. This coating film has a slightly more inferior critical scratch load and micro-hardness. Therefore, to improve both the scratch strength and micro-hardness of the (Al,Cr)N coating film, the cathode material of an alumi-num/chromium/tungsten target was used in adding the tungsten (W) to the cathode material of the alumi-num/chromium target. To clarify the effectiveness of the aluminum/chromium/tungsten-based coating film, we measured the thickness, micro-hardness and critical scratch strength of aluminum/chromium/tungsten-based coating film formed on the surface of a substrate of cemented carbide ISO K10 formed by the arc ion plating process. The hardened steel ASTM D2 was turned with the (Al,Cr,W)N, (Al,Cr,W)(C,N), (Al,Cr)N and the (Ti,Al)N coated cemented carbide tools. The tool wear of the coated cemented carbide tools was ex-perimentally investigated. The following results were obtained: (1) The micro-hardness of the (Al,Cr,W)N or (Al,Cr,W)(C,N), (Al,Cr)N coating film was 3110 HV0.25N or 3080 HV0.25N, respectively. (2) The critical scratch load of the (Al,Cr,W)(C,N) coating film was 123 N, which was much higher than that of the (Al,Cr)N or (Ti,Al)N coating film. (3) In cutting the hardened steel using (Al,Cr,W)(C,N) and (Ti,Al)N coated carbide tools, the wear progress of the (Al,Cr,W)(C,N) coated carbide tool was almost equivalent to that of the (Ti,Al)N coated carbide tool. The above results clarify that the aluminum/chromium/tungsten-based coating film, which is a new type of coating film, has both high hardness and good adhesive strength, and can be used as a coating film of WC-Co cemented carbide cutting tools.

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